Numerical finite-difference simulations of a two-dimensional transient fast convection-slow diffusion model of the temperature field in orthogonal cutting, due to Tlusty, have been shown to provide better predictions of the peak temperature during orthogonal cutting of AISI 1045 steel, than a commercial finite-element method (FEM) code that uses a conventional Johnson-Cook model for the material constitutive response. An analysis of the simpler Tlusty model is used to argue that the reason it gives better predictions than the FEM code is that the material has a stiffer response to shearing forces, under the conditions of rapid heating, high temperature, and high rate of deformation that are present in high-speed machining, than the response that is measured using conventional pre-heating methods, prior to compression testing, to obtain the constitutive response. Some recent experimental data from the NIST Pulse-Heated Kolsky Bar Laboratory are presented to support this hypothesis.

Proceedings:

Proceedings of ICTAM 2012, the 23rd International Congress of Theoretical and Applied Mechanics